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21st National Award for Excellencein Energy Management 2021
UltraTech Cement Limited
Unit: Dalla Cement Works
Presenters:
1.Prasnth Tripathi -FH-Technical
2.Shishir Pali -HOD Technical Services
3.Neeraj Pundir-SH WCM
Cement Production stopped 22 days
Line-1 Kiln stopped 44 days
Line-2 Kiln stopped 19 days
Impact of COVID 19
Note- No major Impact on Plant Production & Dispatch
Company Profile
1972 • Dalla cement plant started by Govt of India.
1973-74• Expanded with most modern and biggest plant of Asia in
1974 and inaugurated by Hon’ble former Prime Minister of
India Late Smt. Indira Gandhi.
• M/S Jaiprakash associates ltd. acquired the company
started line-1 with 0.5 MTPA2006-07
2008-09
• 12th June UTCL took over from Jaypee & Production started on 29th June’2017.
• Line-2 commissioned with 1.5 MTPA clinker
2017-18
2019-20 • PPCWR cement grade
grinding started
2020-21• WHRS project
with 13.5 MWH
started
GOOD
710
715
720
725
FY18-19 FY19-20 FY20-21
723.19
718.55716.2
Specific Heat Consumption
5800
5950
6100
FY18-19 FY19-20 FY20-21
59675980 6007
Cement Dispatch (Million MT)Kiln TPD
GOOD
0.64% improved 0.33%
improved
0.22% improved
0.45% improved
PLANT PERFORMANCE
646668707274
FY18-19 FY19-20 FY20-21
73.07
68.7067.22
Cement Dispatch (Million MT)Sp. Power Up to Clinkerisation (KWH/MT Clk)
68707274767880
FY18-19 FY19-20 FY20-21
78.68
76.14
72.57
Cement Dispatch (Million MT)Overall Sp. Power Cons. (KWH/MT cement)
GOOD
GOOD
3.22% improved 4.70%
improved
5.98% improved 2.17%
improved
26
28
30
32
34
FY18-19 FY19-20 FY20-21
32.16 32.25
29.05
Cement Dispatch (Million MT)Cement grinding sp.power: Total- (kWh/MT)
GOOD
0.28% increased /CM-2 shell
damaged 9.92% improved
0
2
FY18-19 FY19-20 FY20-21
1.170.83 0.95
Cement Dispatch (Million MT)Sp. Power Packing plant(KWH/MT Clk)
29.06% improved
-14.46% increased
PLANT PERFORMANCE
GOOD
25
30
35
FY18-19 FY19-20 FY20-21
32.16 32.08
28.49
Cement Dispatch (Million MT)Cement grinding sp.power: PPC- (kWh/MT)
25
30
35
FY18-19 FY19-20 FY20-21
0
35.75
32.53
Cement Dispatch (Million MT)Cement grinding sp.power: PPCWR- (kWh/MT)
0.25% improved 11.19%
improved
No PPCWR
9.01% improved
GOOD
PLANT PERFORMANCE
Unit Energy Performance ComparisonWith benchmark (Year 2020-21)
Overall sp. Power Consumption (kWh/MT cement)
Sp. Heat Consumption (Kcal/kg clinker)
Ref. For National Benchmark : - CII Energy benchmarking for cement Industry Ver-5, May 2021Ref- For International Benchmark Report of Industrial Energy Efficiency Benchmarking Report for Cement Sector by United Nations Industrial Development Organization (UNIDO).
GOOD
GOOD667.00
676.00
715.00 716.17
770.11
698.12
620
645
670
695
720
745
770
795
Globalbenchmark
Nationalbenchmark
Plant Target FY 20-21 TotalSHC
FY 20-21 (Line-1) FY 20-21 (Line-2)
Line-1 is 1970’s plant with old grate cooler
56.14 56.14
70.0072.57
50
55
60
65
70
75
80
85
Global benchmark National benchmark Plant Target FY 20-21 DLCW
© Confederation of Indian Industry
Road Map for Benchmarking- FY22 projects
Action Plan Status
Retrofitting/ replacement/ In-house modification of Energy efficient fans at Major Fans.
Proposal in progress
Increasing TSR by executing CAPEX for AFR feeding systemCapex approved/ordering started
Exploring for replacement existing Cooler with high efficiency cooler
Line-2 completed & Line-1 proposal in progress.
Retrofitting old reciprocating compressor to high efficiency screw compressor
Audit completed / proposal in progress
Upgradation line-1 preheater for 2250 TPD capacity. Proposal in progress.
Increasing fly ash addition in PPCWR from 30 to 32% and reduction of conversion factor.
Continuously improved
Increasing Line-2 VRM output & reduction SPC by addition of RP rejects to VRM
Project started
GtG energy consumption status
PAT Status-DLCW after UTCL
799
756
811
763
734
702
600
650
700
750
800
850
2014-15 (BaselineYears)
Target 2017-18 2018-19 2019-20 2020-21
kcal/MT Cement eq.UTCL took over DLCW from M/S Jaypee Associates Ltd at June’17.5.92%
reduction
3.80% reduction
4.36% reduction
Achieved 7.14% reduction in FY 2020-21 from given target
5.SUMMARY OF ENCON MEASURES TAKEN IN
LAST THREE YEARS
5.Energy saving initiatives in Last Three Years
Year No of energy saving
projects
Investments (INR
Million)
Electrical Saving
(Million kWh)
Thermal Saving
(MillionKcal)
Saving (INR
Million)
Impact on electrical kWh/MT cement,
Thermal (Kcal/kg clk)
FY 2018-19 13 8.20 1.84 8458.59 17.65
SEC reduced 8.65% (7.45kWh/MT cmt) fromprevious FY and 6.74kcal/kg clk saving ofthermal energy.
FY 2019-20 17 7.35 1.48 7953.75 15.52
SEC reduced 3.22% (2.53kWh/MT cmt) fromprevious FY and 4.41kcal/kg clk saving ofthermal energy.
FY 2020-21 15 14.30 6.05 12896.67 40.84
SEC reduced 4.70% (3.58kWh/MT cmt) fromprevious FY and 2.38kcal/kg clk saving ofthermal energy.
0
5
10
15
FY18-19 FY19-20 FY20-21
8.27.35
14.3
Investment in INR Million
0
3
6
9
FY18-19 FY19-20 FY20-21
1.84 1.48
6.05
Electrical Saving Million kWh
Unit Performance – Last Three Years
5000
8000
11000
14000
FY18-19 FY19-20 FY20-21
8,458.59 7,953.75
12,896.67
Thermal Saving Million Kcal
Project 1- Energy saving by smoke chamber modification
Objective:-Reduction in electrical & thermal energy.
Backdrop:-Line-1 Kiln is having 4 stage suspension preheater without any secondary firingarrangement in preheater so Kiln output couldn’t get increased due to single firingsystem & also higher velocity at kiln inlet due to small smoke chamber design.
Due to very old civil structure (i.e. 40 years old) of preheater building, addition incyclones stages & modification of risers were not possible during annual shutdown.
Line-1 pre clinkerisation sp. power consumption was higher 83.72 kWh/MT clk.
Line-1 sp. heat consumption also higher 783.75 kcal/kg clinker.
Higher Preheater exit temperature & lower kiln output due to old design
Project 1- Energy saving by smoke chamber modification
Approach:• For improving the performance of line-1 Kiln, a cross
functional team formed & discussed the best possiblemodification within annual shutdown.
• Based on the discussion team proposed to modify thekiln smoke chamber by 500 mm of size enlargementand secondary firing in kiln inlet.
• During the annual shutdown (April’20) of Line-1 kilnarea following jobs done-
• Area enlargement of smoke chamber.
• Installation of secondary firing in smokechamber.
After the modification done, it was decided to runthe kiln without secondary firing for optimum Sp.Heat Consumption & kiln output and we get thebenefit of ~50 TPD without increase in heat.
We continued with enlarged area for optimizing thefeed.
500 mmEnlarged
Project 1- Energy saving by smoke chamber modification
Results:• Kiln output increased by 44 TPD from previous FY
• Achieved saving in sp.heat consumption by 13.64 kcal/kg clk from previous FY
• Achieved saving in kiln sp. power cons. is 4.21 kWh/MT clk from previous FY
Parameter UOMBefore
(FY 2019-20)After
(FY 2020-21)Saving
Production MT 423987 447829 23842
Output TPD 1481 1525 44
Sp.heat Cons. Kcal/Kg clk 784 770 13.64
Total Sp.power Cons.
kWH/MT Clinker
30.47 26.26 4.21
Line-1 Pre Clinker SPC
kWH/MT Clinker
83.72 76.25 7.47
Cost of power Rs/Kwh 3.5
Cost of heat Rs/MCV 1150
Saving in (INR Lakhs/Annum) from energy saving 136.22
Benefits Achieved:
• Saving: 136.22 Lakh INR.
• ROI within 2 Months.
• GHG Emission reduced by
8.94 kgCO2/MT Clk.
• PH exit temperature
reduced by ~17 Deg C.
Project 2- Energy saving grinding media optimisation
Objective:-Electrical energy saving by optimising grinding media in open circuit ball mill for cement grinding.
Issues:-• Unit have 02 nos. very old design open circuit ball mills with capacity of 35 tph in
PPC grade• Main drive itself consumes 85% of total cement grinding power
consumption. To reduce Sp.power in cement grinding either main drive loadshould be reduced or mill output to be increased in same loading.
• Mill auxiliary specific power consumption including mill vent fan was on
higher side due to low output.
Project 2- Energy saving grinding media optimisation
Approach:Brainstorming session done with departmental teams and Team finalised the followingideas for grinding media optimisation & production improvement and the same wasimplemented.
1) 15 mm grinding media removed & 17 mm & 20 mm increased in second chamberof mill. Media loading reduced by 6% from previous (33% to 27%).
2) Higher percentage of Line-2 clinker mixed as C3S is higher in Line-2 clinker.
Project 2- Energy saving grinding media optimisation
Results:
• Cement Mill output increased by 2.44 TPH from previous FY
• Achieved saving in cement grinding sp.power consumption by 3.20 kWh/MT
Cement from previous FY
Benefits Achieved:
• Saving: 57.03 Lakh INR.
• ROI with in 5 Months.
• GHG Emission reduced by 2.62 kg CO2/MT Cement
Parameter UOMBefore
(FY 19-20)After
(FY 20-21)Saving
Production MT 443864 509804 65940
Output TPD 30.67 33.10 2.44
Total Sp.power Cons.
kWH/MT Cement
32.25 29.05 3.20
Cost of power Rs/Kwh 3.5
Saving in (INR Lakhs/Annum) from energy saving 57.03
Utilization of Renewable Energy sources
Year FYTechnology(Electrical)
Type of Energy
Onsite/ off site
Installedcapacity (MW)
Generation(Million kWh)
% Of overall elect energy
FY 2018-19 - - - - - -
FY 2019-20 - - - - - -
FY 2020-21 - - - - - -
• Solar lights installed in colony street lights• Solar water heater installed in colony guest houses 12 KW• WHRS project (13.5 MW) erection in progress, Expected commissioning Aug’2021• Proposal submitted for 2.5 MW Solar plant
Utilisation of Waste Material as Fuel
S.No. Year FY Total Alf fuels Quantity (MT)
Wt. Avg NCV (kcal/kg clk)
Waste as percentage of total fuel
1 FY 2018-19 3006 1284 0.30
2 FY 2019-20 3070 1878 0.41
3 FY 2020-21 2930 2840 0.65
0.22
0.3
0.41
0.65
0
0.3
0.6
0.9
% TSR
2017-18 2018-19 2019-20 2020-2021
Utilisation of Waste Material as Fuel FY 2020-21
FY 2020-21-UTCL DALLA CEMENT WORKSCOAL QTY NCV Heat (Mkcal) QTY (Total) NCV (kcal/kg) Heat (Mkcal) AFR in Heat %
CARBON POWDER 25.00 6,111.69 152.79
2,930 2840 8322.58 0.65
CLOTH WASTE 81 3,523.97 285.44FMCG WASTE 1,378.89 2,139.34 2949.91MSW RDF 101.56 2,897.28 294.25OWN WASTE 24.7 2,639.36 65.19PLASTIC WASTE 1,182.13 3,442.05 4068.95SOLID WASTE 67.78 3,794.03 257.16WOODEN DUST 69.02 3,606.00 248.89
Utilisation of Waste Material as Additive
Waste material used as Alternative Raw Material (Additive)
Sl.No Waste MaterialQuantity Used (MT)
FY 2018-19 FY 2019-20 FY 2020-21
1 Fly Ash Dry 90,292 97,484 1,11,959
2 Fly Ash TPP 52,725 53,602 53,998
3 Fly ash TPP Coarse 9,920 1,868 8,398
4 Pond ash 0 0 423
5 Chemical Gypsum 98 5,685 6,222
6 Gypusm imported 14,409 6,293 5,999
7 Gypsum Phoshpo 392 693 0
8 Red mud 64,262 79,671 86,347
9 Iron refines 2,168 337 0
Total 2,34,266 2,45,634 2,73,345
% Waste used against natural resource consumption
11.30 11.37 9.51
CO2 Emissions (kg CO2/ton of Cementitious product)
GHG Inventorisation
812.6
778.21
756.42 755
725.00
750.00
775.00
800.00
825.00
FY 2017-18 FY 2018-19 FY 2019-20 FY 2020-21
CO2-Emissions-kgCO2/MT Cement
Go
od
Target Reduction for CO2 emission intensity by 25% by 2025
CO2 Emission Reduction Action Plan
Action Plans Status
Increasing fly ash addition up to 32% in PPCWR Started
WHRS installation (13.5 MWh) Erection in progress
Increasing alterative fuel consumption up to 10% TSR from 1% Ordering in Progress
Installation OLBC to reduce diesel consumption and TAT Project finalised
Installation 2.5 MWh Solar plant in plant boundary To be finalised
Upgradation Line-1 cooler to reduce Thermal energy consumption
Audit completed & Proposal in progress.
Up to FY 2020-21 survived Trees 38621 Nos.
Cumulative Survival rate = 79.895%
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Tree Plantation
38560
4133444675
48340
FY-18 FY-19 FY-20 FY-21
Tree Plantation
Learning from CII Award
This Platform appreciate the
efforts done toward energy conservation
This Platform motivate us to be
the beast in cement
manufacturing among the key
players
This Platform give us energy to
achieve the our energy target
within stipulated timeline.
This Platform creates
competitive culture within the
Plant.
Team Work, Employee involvement & Monitoring
Online process parameter & Energymonitoring through KM
Energy Consumption (SPC & SHC)monitoring through CCR Desk
Loss Matrix
Improvement Projects-Operating Teams
Suggestions-Operating Teams
SII Team/Operating team Monthly
meeting
WCM team meetings
Energy mapping & Balancing
Section wise Budgeting
PLC Based Energy Monitoring System
Relative Monitoring of TPP, RSEB, IEX Cost
Daily Power report
Daily production Report/Meeting
Monthly Comparison-Benchmark Units
Monthly MPR Meeting
Energy Audit through CETS
Benchmarking
Monthly P&B Data on Group Units
Monthly Capex/ Energy Meeting
Approach, Deployment & Review- Improvement Projects /Kaizen/Suggestions
Action by WCM
Shop floor Teams
Kaizens Operating Teams
WCM steering committee meeting
Mechanical Workshop Power Plant
Wage board Employee Interaction Mines Function
Involvement of Employees and Recognitions
ISO 5001 : 2018
We are proud to achieve the
certification without any major
observations
31
National Energy Conservation Award 2017 (First Prize)
Dalla Cement Works awarded as “Excellent Energy Efficient Unit” under CPP Cat.
“21st National Energy Management Award Summit 2020”